Mar. 04, 2025
As a key link in modern industry, the industrial silicon furnace industry consumes huge amounts of energy. According to statistics, China consumes more than 13,000 kWh of electricity for every ton of industrial silicon produced. If 1 million tons of industrial silicon are produced annually, the electricity consumption will be as high as 13 billion kWh or more. Given that China is committed to building a resource recycling system for the whole society and deepening energy conservation and emission reduction, the industrial silicon industry, as a major energy consumer, has made it imperative to recycle waste heat from flue gas.
In order to respond to the country's call to build a conservation-oriented society, while reducing corporate costs and enhancing market competitiveness, it is particularly important to implement energy-saving technology transformation, recover waste heat, and improve comprehensive energy efficiency. At present, research on power generation technology from waste heat from flue gas of industrial silicon furnaces is in-depth.
Industrial silicon furnace flue gas waste heat has the following characteristics: first, it is medium-temperature waste heat, with less waste gas flow and relatively low thermal grade; second, the parameters of flue gas waste heat (such as temperature and flow) flue gas waste heat have a large fluctuation range; third, the silica ash (silicon powder) in the flue gas is extremely fine, has strong adhesion, and has high thermal resistance. After the heated outer tube wall is adhered to the ash, the heat exchange rate will be significantly reduced.
An industrial silicon furnace plant originally had two submerged arc furnaces. The high-temperature flue gas (400℃~600℃) discharged by the factory was cooled to 220℃~230℃ by mixed air, and then first entered the double-effect cyclone dust collector for dust removal. The dust (SiO2 powder) obtained by dust removal is discharged and packaged by the unloader. The flue gas after dust removal is cooled down again by spraying cooling water before entering the fan, so that the temperature of the flue gas drops to about 180℃~200℃, and then enters the bag filter for purification through the induced draft fan, and finally discharged into the atmosphere. Although this treatment method can meet environmental protection requirements, it consumes a lot of electricity and water resources, and the heat energy of high-temperature flue gas is not reasonably utilized, resulting in heat energy waste.
The flow and temperature parameters of high-temperature flue gas determine the installation plan of the waste heat power station, while the smoke composition and its content determine the cleaning method of the waste heat boiler. According to on-site measurements, the flue gas waste heat parameters of the two submerged arc furnaces in the industrial silicon plant are as follows: the total flue gas volume is 2×70000Nm³/h, the flue gas temperature is 450℃, the smoke dust components are SiO₂ (86%~90%), Al₂O₃ (0.2%~1.7%), Fe₂O₃ (0.3%~6.0%), CaO (0.2%~0.5%), and the smoke dust content is 7g/Nm³.
According to the mature waste heat power generation process, the temperature of the flue gas can be reduced to about 200℃ after being used by the waste heat boiler. According to calculations, the waste heat of flue gas that can be used per hour by each submerged arc furnace is 2415×10⁴kJ/h. Considering the efficiency of the waste heat boiler and the generator set, the installation plan for this project is determined to be 2×8t/h silicon industry flue gas dedicated waste heat boiler and 1×3MW pure condensing steam turbine generator set.
The high-temperature waste heat flue gas generated by silicon refining is sent to the waste heat boiler through the flue for heat exchange, and the high-temperature and high-pressure steam generated drives the steam turbine generator set to generate electricity. The cooled flue gas enters the original dust collector for dust removal and is discharged. The power generated by the generator is stepped up by the step-up transformer and connected to the busbar of the silicon furnace 35kV distribution device to achieve grid-connected operation, and all the power generated is used for the load of the entire plant.
In order to improve energy utilization efficiency, according to the principle of flue gas waste heat cascade utilization, the heat of the utilized flue gas can still be used to generate waste heat boiler supplementary steam after it comes out of the waste heat boiler. The flue gas with further reduced temperature can be used to generate hot water, and the flue gas finally cooled to below 120℃ can be treated in the bag filter in accordance with the standard.
The flow rate, temperature and other parameters of high-temperature waste heat flue gas are crucial to the rated output and economic benefits of waste heat power plants. However, most industrial silicon plants cannot provide flue gas monitoring parameters, and there are dangerous factors such as high-temperature live electricity operations and high-altitude falls on site. Therefore, it is recommended to entrust a professional thermal measurement team to conduct field measurements to obtain direct original design parameters.
Most industrial silicon plants lack unified planning during construction, and the use of sites is limited. Therefore, how to use limited sites to reasonably arrange new facilities to meet project requirements, save land, and facilitate management is a major issue facing the design. It is recommended to collect the original design data of the original plant buildings and structures and their foundations, and consider using the original equipment supports and hangers and plant area pipe racks for design under the premise of reliability, economy and conducive to the optimization of the general layout. Otherwise, all new construction should be considered, which puts higher requirements on the optimization layout of the general plan of the waste heat power station.
Waste heat boiler is one of the key equipment of the project. The silicon micropowder in the industrial silicon flue gas is extremely fine, has strong adhesion and high heat resistance. If it is not cleaned up, it will affect the normal operation of the boiler. Taking into account the heating surface form and cleaning method, this project selected a waste heat boiler with acetylene (C₂H₂) deflagration and ash removal method on the heat pipe light pipe heating surface. It is suggested that similar projects should increase the efforts to collect funds, understand the main heating surface forms and cleaning method combinations of waste heat boiler plants through investigation and visits, and then select suitable waste heat power generation boilers based on the actual flue gas parameters of the project.
The successful implementation of the industrial silicon furnace comprehensive utilization of waste heat power generation project will optimize the energy use of the enterprise production system, improve energy utilization efficiency, reduce product costs, achieve energy conservation and consumption reduction, and enhance the sustainable development capabilities of the enterprise. At the same time, it also plays a positive demonstration and promotion role in the large-scale energy conservation, emission reduction and comprehensive utilization work in the regional industry.
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The 5 ton electric arc furnace for steel-making is a special purpose equipment that makes ordinary steel, quality carbon steel, alloy steel and non-corrosive steel with electric arc as heat source and scrap steel (iron) as raw material.
15-ton electric arc furnace is used for the short-process steelmaking process, using 100% scrap steel or scrap steel + molten iron (pig iron), or scrap steel + sponge iron (DRI) as raw materials for steelmaking.
The 30-ton AC electric arc furnace is used to melt scrap steel to produce steel. Electrical energy is used to melt scrap steel. An arc forms between the charged material and the electrode.
30 Ton electric arc furnace is used for steelmaking short process smelting, using 100% scrap steel or scrap steel + molten iron (pig iron), or scrap steel + sponge iron (DRI) as raw materials for steelmaking.
The 50-ton ultra-high power electric arc furnace (50TUPH EAF) adopts ultra-high power, high impedance technology, bottom tapping technology (ETB), furnace wall oxygen oil burner and furnace door carbon-oxygen gun technology.
DC electric arc furnace is an electric arc furnace supplying electric energy with DC power supply. There is only one electrode on the top of the DC arc furnace, which is the negative electrode, and the bottom electrode is the positive electrode.
Electric arc furnaces are used to melt scrap steel for steel production. Electrical energy is used to melt scrap steel. An arc forms between the charged material and the electrode. The heat generated by the arc melts the scrap.
Electric arc furnace steel making is a steelmaking method that uses the thermal effect of electric arc to heat the charge for melting.
Ultra-high power electric arc furnace mainly changes the arc characteristics of high voltage and long arc to the arc characteristics of high current, low voltage and short arc
1 ton electric arc furnace is used for melting steel and titanium scrap metal. The principle of electric arc furnace is based on the generation of direct current, which converts electrical energy into heat energy through electrodes to melt the metal.
The closed pig iron furnace (submerged arc furnace iron making) is a non-blast furnace iron making method. Under the premise of guaranteeing the power supply, it is easy to solve the problem by using the reducing agent required by the submerged arc furnace iron making.
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The Ferronickel submerged arc furnace is a special submerged arc furnace used for smelting nickel-iron alloy. Its main function is to add nickel ore, carbonaceous reducing agent (such as coke) and limestone and other raw materials into the furnace in a certain proportion
The main mechanical device design of Sanui ferrosilicon furnace combines China's national conditions and draws on international advanced technologies such as Demark and Pyremate.
The main mechanical device design of Sanui high carbon ferrochrome furnace combines China's national conditions and draws on international advanced technologies such as Demark and Pyremate.
Industrial silicon submerged arc furnace is an important equipment in silicon ore processing, playing a key role in the silicon industry.
The manganese silicon alloy furnace is mainly used to smelt silicon-manganese alloy, which is an alloy containing silicon and manganese.
The design of the submerged arc furnace main mechanical device by Sanui is based on China's national conditions and draws on international advanced technologies such as Demark and Perlmutter.
Submerged electric arc furnace is mainly used for reducing and smelting raw materials such as ore, carbonaceous reducing agent and solvent. It mainly produces ferroalloys such as ferrosilicon, ferromanganese, ferrochrome, ferrotungsten, silicon-manganese alloy, etc.
Titanium slag production adopts titanium slag electric furnace (circular furnace and rectangular furnace according to its shape) smelting process.
The LF 20 T ladle refining furnace has the functions of arc heating under normal pressure, argon blowing and stirring at the bottom of the ladle, and reducing slag making in the ladle.
LF ladle refining furnace is a bottom-blown argon ladle furnace with three-phase submerged arc heating under normal pressure. It is a device for refining molten steel in a ladle.
VD vacuum refining furnace is a commonly used refining process equipment, mainly used for deoxidation, impurity removal and other operations of molten steel, so as to obtain high purity, low impurity content of high quality steel.
VOD vacuum refining furnace has multiple functions such as vacuum degassing, oxygen blowing decarburization, vacuum charging, argon blowing stirring, non-vacuum temperature measurement sampling, wire feeding, etc.
The cast steel melting induction furnace has outstanding advantages in heat penetration or melting soft magnetic alloys, high resistance alloys, platinum group alloys, heat-resistant, corrosion-resistant, wear-resistant alloys and pure metals.
Metal silicon smelting furnace is a metal silicon medium frequency melting furnace, which consists of furnace body, water and electricity introduction system, furnace tilting device, etc. It has fast melting temperature rise, easy to control furnace temperature and high production efficiency.
Medium frequency induction furnace mainly used for melting steel, alloy steel, special steel, stainless steel, and can also be used for melting and casting non-ferrous metals such as copper, aluminum, lead, zinc, etc. The customized range of induction furnaces sold by Sanrui ranges from 0.1 tons to 10 tons.
Medium frequency induction furnaces are mainly used for melting steel, alloy steel, special steel, stainless steel, and can also be used for melting and casting non-ferrous metals such as copper, aluminum, lead, and zinc.
Medium frequency aluminum melting furnace is used for melting and heating aluminum, scrap aluminum, aluminum ingots, and aluminum alloys; The melting capacity ranges from 100KG to 3000KG.
An induction furnace is an electric furnace that uses the induction electrothermal effect of the material to heat or melt the material. The main components of an induction furnace are sensors, furnace body, power supply, capacitors and control system.
The 3-ton medium frequency coreless induction furnace adopts a 6-phase 12-pulse double rectifier control system. A 2000KVA special rectifier transformer is used for the 2000KW medium frequency power supply.
The conductive arm of an electric arc furnace (EAF) is primarily composed of the front electrode conductive arm holder, a water-cooled clamping ring, the arm body, and the rear conductive copper plate.
The scrap charging basket of the electric arc furnace is mainly used for loading and conveying raw materials such as scrap steel into the electric arc furnace for smelting.
There are many insulation links between the EAF electrode holder and the conductive cross arm body, which greatly simplifies the cconductive cross arm structure and is a new type of electrode arm on the ultra-high power arc furnace.
Generally, the furnace cover of the electric arc furnace adopts the tubular water-cooled closed tube furnace cover structure.
The electrode lifting mechanism of electric arc furnace is composed of conductive cross arm and electrode column device.
Forged copper tile is one of the main accessories in submerged arc furnace (silicon metal furnace, calcium carbide furnace and iron alloy furnace). It generates heat energy due to passing through large current at high temperature, and is easy to be damaged due to poor working environment.
The furnace cover lifting and rotating device consists of a furnace cover lifting mechanism, a rotating mechanism and a rotating frame.
Submerged arc furnace pressure ring is used to monitor the change of air pressure in the furnace in real time, and adjust the air pressure automatically or manually according to the preset parameters to ensure the stability of air pressure in the furnace
Submerged arc furnace water-cooled Roof is an important part of submerged arc furnace (also known as electric arc furnace, calcium carbide furnace or mining furnace), which is mainly used to close the top of furnace body and bear the high temperature and pressure in the furnace.
Short network bus systems), also known as high current line, refers to the general term of the carrier fluid from the secondary outlet terminal of the transformer to the electrode (including the electrode).
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